2134/7472
D.J. Parrish
D.J.
Parrish
A flexible manufacturing system for lawnmower cutting cylinders
Loughborough University
2010
untagged
Mechanical Engineering not elsewhere classified
2010-12-02 10:24:00
Thesis
https://repository.lboro.ac.uk/articles/thesis/A_flexible_manufacturing_system_for_lawnmower_cutting_cylinders/9523529
The thesis is concerned with the conception and design of a FLEXIBLE
MANUFACTURING SYSTEM (FMS) for the automation of the manufacture of
lawnmower cutting cylinders at Suffolk Lawnmowers Ltd. A review of FMS
definitions, planning methods and current systems is carried out for the
development of a suitable FMS configuration for the final stages of
manufacture of grass cutting cylinders having 21 different design
specifications. This involves examination of the capabilities of
robotics and microcontrollers to automate the technologies used in
cylinder production.
The company's current manual batch production system is analysed to
determine the suitable form and requirements of the FMS. This includes
analyses of annual volumes, throughputs, batch sizes, product and process
mixes. Long term objectives to automate the system are identified from
which short term objectives are derived. The FMS recommended for
immediate development encompasses the short term objectives for the
welding, hardening, grinding and transfer processes of 8 cutting cylinder
specifications.
It is shown that the MIG (Argon/C02) are welding, progressive flame
hardening and wide-face cylindrical grinding processes can be developed
successfully to automate cylinder production. The recommended system
integrates these processes into an FMS through the'automatic handling
of cylinders (through three process routes) by a robotic manipulator
utilising a double gripper. 'A robotic welding station, manually loaded,
is also recommended. ' The system is controlled overall by a 32K microcontroller
with the process machines individually controlled by programmahle
logic controllers with up to 6K of memory each.
The economic appraisal of the FMS indicates a 4.4 year payback based on
direct labour and material cost savings. The company's application for
grant aid to implement the FMS design has led to an offer of a Department
of Industry grant to cover 50% of all capital and revenue costs. The
grant of £166,943 reduces the payback period to 2.3 years.